Thin-walled plastic hat

Abstract

A one-piece, lightweight, molded plastic hat that comprises, in combination, a thin, molded plastic sheet forming a hat wall dome having an inner side, the sheet at the dome everywhere having thickness less than 3/16 inch; the sheet at the dome forming a corrugation having a local portion defining a U-shaped cross section; and a local plastic reinforcement sub-sheet formed to have U-shaped cross section matching that of the dome local portion, the sub-sheet fitting and adhesively bonded to the dome sheet local portion at the inner side of the hat dome.

I claim: 
     
       1. A one-piece, lightweight, molded plastic hat comprising, in combination: a) a thin, molded plastic sheet forming a hat dome having an inner side, said sheet having a substantially uniform thickness of less than 3/16 inch,   b) said sheet forming a corrugation having a local portion defining a U-shaped cross section,   c) and a local plastic reinforcement sub-sheet having a U-shaped cross section matching that of said local portion, said sub-sheet fitting and adhesively bonded to said sheet local portion at said inner side of the hat dome.   
     
     
       2. The combination of claim 1 wherein said dome local portion has lengthwise elongated extent and said U-shaped cross section is defined everywhere along said elongated extent. 
     
     
       3. The combination of claim 2 wherein said reinforcement sub-sheet also has a lengthwise elongated extent and said U-shaped cross section matches that of said local portion everywhere along said elongated extent thereof. 
     
     
       4. The combination of claim 3 wherein said reinforcement sub-sheet has a thickness less than 1/4 inch. 
     
     
       5. The combination of claim 1 wherein said reinforcement sub-sheet has a thickness less than 1/4 inch. 
     
     
       6. The combination of claim 1 wherein said sub-sheet has a maximum overall length in excess of 1 inch. 
     
     
       7. The combination of claim 1 wherein d) said hat dome has a lower looping portion having an inner side for reception over a wearer's head, said lower looping portion also consisting of said molded plastic sheet,   e) multiple plastic thin-walled carriers bonded to said inner side lower looping portion,   f) said carriers each having thin sheet configurations,   g) said carriers and said hat dome forming slots for retention of a head-supporting harness structure.   
     
     
       8. A one-piece, lightweight, molded plastic hat, comprising: a) a thin, molded plastic sheet forming a hat dome having an inner side, said sheet having a substantially uniform thickness of less than 3/16 inch,   b) said sheet forming a corrugation having a local portion defining a U-shaped cross section,   c) and a local plastic reinforcement sub-sheet having a U-shaped cross section matching that of said local portion, said sub-sheet fitting and adhesively bonded to a said local portion at the inner side of the hat dome, said reinforcement sub-sheet having a lengthwise elongated extent.   
     
     
       9. The hat of claim 8 wherein said reinforcement sub-sheet has a thickness less than 1/4 inch. 
     
     
       10. The hat of claim 8 wherein said sub-sheet has a maximum overall length in excess of 1 inch. 
     
     
       11. The hat of claim 8 wherein: d) said hat dome has a lower looping portion having an inner side for reception over a wearer's head, said lower looping portion also consisting of said molded plastic sheet,   e) multiple plastic thin-walled carriers bonded to said inner side lower looping portion,   f) said carriers each having thin sheet configurations,   g) said carriers and hat dome forming slots for retention of a head-supporting harness structure.